Laser-based lap welding of sheet metal components using laser induced protuberances to control gap

1. A method for laser welding first and second components, comprising:

using a remote welding head that is in communication with a laser source, moving a laser beam across a portion of a surface of the first component at a scan speed sufficient to generate a series of protuberances along a laser-produced bead on the surface of the first component by means of a humping effect, wherein the laser beam does not melt an entire thickness of the first component along the laser-produced bead;

juxtaposing said first and second components such that opposed surfaces of the first and second components are separated by protuberances of said series of protuberances on the surface of the first component; and

laser welding said first and second components by scanning the laser beam, from the remote welding head and the laser source, in a region in which said surfaces are separated by said protuberances;

controlling a height of the protuberances by controlling the scan speed of the laser beam; and

wherein the scan speed is from 25 to 80 m/min.

2. The method as defined in claim 1 wherein the first and second components are made from metal or metal alloy and wherein at least one of the first and second components is coated with a material having a vaporizing temperature that is lower than a melting point of the metal or metal alloy.

3. The method as defined in claim 2 wherein the first and second components are made from steel.

4. The method as defined in claim 2 wherein the first and second components are coated with at least one of zinc, zinc oxide, magnesium, and magnesium oxide.

5. The method as defined in claim 1 wherein the series of protuberances create a pattern corresponding to a welding pattern generated by the laser welding step.

6. The method as defined in claim 1 wherein the series of protuberances create a pattern different from a welding pattern generated by the laser welding step.

7. The method as defined in claim 1 further comprising clamping the first and second components to each other prior to the step of laser welding.

8. The method as defined in claim 1 further comprising controlling a height of the protuberances by controlling an intensity of the laser beam.

9. The method as defined in claim 8 wherein controlling the intensity of the laser beam includes controlling a laser power and a beam spot size of the laser beam.

10. The method as defined in claim 8 wherein the height of the protuberances is from 0.1 to 0.2 mm.

11. The method as defined in claim 1 wherein the height of the protuberances is from 0.1 to 0.2 mm.

12. The method as defined in claim 1 wherein the scan speed is from 60 to 80 m/min.

13. A method of laser welding first and second components comprising:

using a remote welding head that is in communication with a laser source, moving a laser beam across a portion of a surface of the first component at a scan speed sufficient to generate a series of protuberances along a laser-produced bead on the surface of the first component by means of a humping effect,

wherein the movement of the laser beam across the portion of the surface of the first component is at the scan speed of between 25 to 80 m/min;

wherein the laser beam does not melt an entire thickness of the first component along the laser-produced bead;

juxtaposing said first and second components such that opposed surfaces of the first and second components are separated by protuberances of said series of protuberances on the surface of the first component;

laser welding said first and second components by scanning the laser beam, from the remote welding head and the laser source, in a region in which said surfaces are separated by said protuberances; and

controlling a height of the protuberances by controlling the scan speed of the laser beam.

14. The method as defined in claim 13 wherein the first and second components are made from metal or metal alloy and wherein at least one of the first and second components is coated with a material having a vaporizing temperature that is lower than a melting point of the metal or metal alloy.

15. The method as defined in claim 14 wherein the first and second components are made from steel.

16. The method as defined in claim 14 wherein the first and second components are coated with at least one of zinc, zinc oxide, magnesium, and magnesium oxide.

17. The method as defined in claim 13 further comprising controlling a height of the protuberances by controlling an intensity of the laser beam.

18. The method as defined in claim 17 wherein controlling the intensity of the laser beam includes controlling a laser power and a beam spot size of the laser beam.